Body - Knocking Noise From Front of Sunroof

NVH
NV016-07

Title:
KNOCKING NOISE FROM FRONT OF
MOON ROOF

Models:
'05 - '08 Avalon

December 21, 2007

Introduction
Some 2005 - 2008 model year Avalon customers may complain of a knocking noise from the front of the moon roof above the driver or passenger's head while driving. Use the repair procedure below to improve this condition.

Applicable Vehicles

^ 2005 - 2008 model year Avalon vehicles.





Required Tools & Material





Warranty Information

This repair is covered under the Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Repair Procedure

1. Confirm that the noise is coming from the area near the front corner of the moon roof (either left or right).

2. Record the radio station presets.

3. Remove the sliding roof housing sub-assembly. Refer to the Technical Information System (TIS):

^ 2005 model year Avalon Repair Manual, Vehicle Exterior - Sliding Roof/Convertible - "Sliding Roof: Replacement"





^ 2006 - 2008 model year Avalon Repair Manual, Vehicle Exterior - Sliding Roof/Convertible - "Sliding Roof Housing: Removal"

4. From the Interior Noise Kit, make two felt strips to the following dimensions:

Length: 300 mm (12.00 in.)

Width: 32 mm (1.25 in.)

Thickness: 0.5 mm ([0.02 in.] thinnest felt sheet material in the kit)





5. Temporarily peel back the backing paper at both ends and make a cut 2 inches (50.8 mm) away from the ends. Place the backing paper back on the felt.

6. Place the felt strip between the roof panel and the moon roof mounting structure panel as shown in the illustration below.

NOTE:
Pull down on the moon roof mounting structure in the area of the front mounting stud to make space for the felt to slide into place.





IMPORTANT:
The felt strip is placed at an approximate 30° angle from the front edge of the moon roof opening.





Once the felt is placed as close to the inner edge as possible, peel off the backing paper at the ends of the felt strip and stick the felt to the roof panel.

7. Perform the felt repair on both front corners of the moon roof structure.

8. Install the sliding roof housing sub-assembly. Refer to TIS:

^ 2005 model year Avalon Repair Manual, Vehicle Exterior - Sliding Roof/Convertible - "Sliding Roof: Replacement"

^ 2006 - 2008 model year Avalon Repair Manual, Vehicle Exterior - Sliding Roof/Convertible - "Sliding Roof Housing: Removal"

9. Reset the radio presets and clock.

For reinitialization procedures refer to the following TSB's:

2005 model year Avalon vehicles, refer to TSB No. PD008-05 "Power System Initialization During PDS".

2006 model year Avalon vehicles, refer to TSB No. PD014-06 "Power System Initialization During PDS".

2007 model year Avalon vehicles, refer to TSB No. PD010-07 "Power System Initialization During PDS".

2008 model year Avalon vehicles, refer to TSB's No.:

^ PD086-07 "Initial Calibration of Compass During PDS".

^ PDO8O-07 "Initialization of Power Window During PDS".

^ PD1 02-07 "Initialization of Sliding Roof During PDS".

^ PD082-07 "Tire Pressure Warning System Initialization".

10. Test drive vehicle to confirm noise is gone.